Co-casting precious metal to an alternative material

ABSTRACT

A Co-Casting technique is described herein using Pins, Undercuts, Grooves, Rails that permit the attachment of a secondary precious metal to a primary alternative meta. The process of making a mold creating a model and casting a final worked piece uses wax filling of the recessed areas and the subsequent molding of the precious metal within the recessed areas in order to fill the aforementioned.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/766,096 filed Feb. 18, 2014, the entirety of which isincorporated by reference

FIELD OF THE INVENTION

The present invention is related to improvements in the attachment ofone type of material to another. More particularly, the presentinvention provides a process whereby a precious metal can be attached toanother material that is not as valuable as the first; this lessvaluable material defined by the jewelry industry as “alternative,”“contemporary,” or “non-traditional.”

BACKGROUND OF THE INVENTION

Just prior to the formation of Spectore Corp in 1983, Edward Rosenberg(Spectore's founder) was one of, if not the only American to pioneer andintroduce refractory metals to the jewelry industry. Through the last 30years contemporary materials (including but not limited to: the entirefamily of refractory metals titanium, niobium, zirconium, and tantalumas well as stainless steel, chrome cobalt and others deemed asalternative, contemporary, and new age materials—hereinafter referred toas “alternative materials” or “AM”) grew to become a staple acceptedfine and fashion jewelry, gift and accessory material. Due to thesupply, demand, and inflation, gold, platinum, silver, palladium, andthe like have further increased in cost to such an extent that theaverage consumer finds it difficult to purchase items made purely of theaforementioned. As a consequence, jewelry retailers and customers havebeen forced by current market trends to cut back on their purchasing ofnow highly expensive items; thus, articles having precious metals suchas rings, bracelets, jewelry, consumer products, giftware, personal andtable top accessories, watches, and any form of decorative encasementshave experienced a general decline in their respective market shares.

Because of this, many have begun to purchase items having materialsoutside of the traditional materials used in the industry; these areknown in the common parlance of the industry as alternative materials.These alternatives were introduced and/or promoted by manufacturersstung by their falling sales; of these, Spectore Corporation was one ofthe principal if not the only pioneer of AM going back as early as 1980.Thus, a growing number of manufacturers have followed suit in that theyrightly reacted to the cost driven decline by shifting production toarticles containing tungsten, titanium, stainless steel, surgicalstainless steel, platifina or rhodium based jewelry and many other typesof alternative materials. As a result, customers now have the choice ofarticles using AM in providing the benefit of an inert material which isincredibly compatible with the skin and is highly durable.

However, people still like precious metal jewelry and there is still agreat demand for these items if some solution to their exorbitant costcould be found. Accordingly, there remains a need in the art for asolution to this problem that overcomes the cited deficiencies of highupfront cost while still providing a valuable, precious metal articlethat conveys value over time.

SUMMARY

The invention provides a process for co-casting precious metal to analternative material that overcomes the hereinafore-mentioneddisadvantages of the heretofore-known devices and methods of thisgeneral type and that

With the foregoing and other objects in view, there is provided, inaccordance with the invention, a co-casting method that includescreating an original design having unique criteria with a recessed areaconnecting a pattern in the design;

In another aspect, the pattern has a minimum depth of 0.5 mm.

In another aspect, the unique criteria ensures that a secondary metaladheres to a primary alternative metal.

In another aspect, wherein each pattern wall has an undercut to permitattachment of a secondary material.

In another aspect, making the original design into a mold.

In another aspect, creating a model using a metal and a pattern thereinis coated with wax filling.

In another aspect, placing the model in an investment sprue.

In another aspect, casting the model with a secondary metal.

In another aspect, removing the model from the investment andimmediately molding it with both metals together.

In another aspect, cleaning and completing the model.

These and other aspects, features, and advantages of the presentinvention will become more readily apparent from the attached drawingsand the detailed description of the preferred embodiments, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will hereinafter be describedin conjunction with the appended drawings provided to illustrate and notto limit the invention, in which:

FIG. 1 presents a short group of images representing the depressions andundercuts, connecting rails and pin co-casting methods;

FIG. 2 represents a general explanation of the method of usingdepressions in co-casting an item;

FIG. 3 represents a general explanation of the method of using rails inco-casting an item; and

FIG. 4 represents a general explanation of the method of using pins inco-casting an item.

Like reference numerals refer to like parts throughout the several viewsof the drawings.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and isnot intended to limit the described embodiments or the application anduses of the described embodiments. As used herein, the word “exemplary”or “illustrative” means “serving as an example, instance, orillustration.” Any implementation described herein as “exemplary” or“illustrative” is not necessarily to be construed as preferred oradvantageous over other implementations. All of the implementationsdescribed below are exemplary implementations provided to enable personsskilled in the art to make or use the embodiments of the disclosure andare not intended to limit the scope of the disclosure, which is definedby the claims. For purposes of description herein, the terms “upper”,“lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, andderivatives thereof shall relate to the invention as oriented in eachindividual figure. Furthermore, there is no intention to be bound by anyexpressed or implied theory presented in the preceding technical field,background, brief summary or the following detailed description. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification, are simply exemplary embodiments of the inventiveconcepts defined in the appended claims. Hence, specific dimensions andother physical characteristics relating to the embodiments disclosedherein are not to be considered as limiting, unless the claims expresslystate otherwise.

The concept taught herein is a laminated precious metal having matchingcontours with an alternative material found underneath. A securing area(hole, undercut, pin etc) or extended surface on the one or more sides(anywhere on piece) of the alternative material forms a convenientsupport piece for attachment of the top precious metal surface. Thus,this securing area(s) can be found anywhere about the surface that oneusing this concept would find it useful to locate a support surfaceabout the alternative material article to be overlaid.

FIG. 1 presents a short group of images representing the depressions andundercuts, connecting rails and/or pin co-casting methods and includesother means as well as each of these techniques may be used alone or incombination. The images depict a ‘groove’ or depression in the surfaceof an article of jewelry made from an Alternative Material such astitanium; this groove or depression is to be filled with anothermaterial having a lower boiling point such as gold, silver etc. . . . .In this context, the word ‘groove’ means a depression that is a hollowedout area in the surface of a material such that the ‘groove’ forms theregion for co-casting of a secondary material into the aforementionedhollow in the structure of a material. The basic process is to firstSKETCH a design of an item then CREATE the DESIGN using CAD/CAM or byhand using wax CARVING. Then, the process may include using 1) ridgesand/or undercuts, 2) connecting rails, and 3) pin co-casting areutilized to cast the two metals together creating a beautiful item.

FIG. 2 represents a process flow diagram relating to the method of usinggrooves, depressions and/or undercuts in co-casting an item. Thisprocess includes:

-   -   a. A wax or CAM part is created having a finished exterior        surface representing the finished article (ring in this example)        as it would be with both the alternative material and secondary        material together; thus, this part is completely full and is        without any undercuts and or grooves therein. It also has a base        having a thin rod sprue connecting the base to the article        itself    -   b. A primary mold is created by inserting the part made in step        ‘a’ by hand or CAM into rubber mold slabs having top and bottom        portions. A mold is made of this model and thus the article can        be duplicated over and over again.    -   c. A wax or CAM part is created having a finished exterior        surface representing the finished article (ring in this example)        as it would be with both the alternative material and secondary        material together; thus, this part is completely full and is        without any undercuts and or grooves therein. It also has a base        having a thin rod sprue connecting the base to the article        itself.    -   d. A production mold is created by inserting the part made in        step ‘c’ by hand or CAM into rubber mold slabs having top and        bottom portions. A mold is made of this model and thus the        article can be duplicated over and over again.    -   e. Then the production mold is utilized to create a finished        article over and over again. A ring or other article that has        been machined with grooves is filled with wax in the grooves        therein and is inserted into the production mold. A secondary        material such as gold or silver is injected into the mold with a        rapid burnout cycle thereby completing the article.

FIG. 3 represents a process flow diagram relating to the use of rails inco-casting an item. This process includes:

-   -   A) A wax or CAM part with a plurality of rails connecting ring        all the way around to trap secondary material forming a complete        ring.    -   B) A primary model is molded.    -   C) The primary model is filled with wax for secondary casting.    -   D) A completed Co-Cast, materials are molded together, then        primary model (2A) is placed inside for secondary wax injection        to repeat process.

Alternative process . . .

-   -   a. A wax or CAM part is created having a finished exterior        surface representing the finished article (ring in this example)        as it would be with both the alternative material and secondary        material together; thus, this part is completely full and is        without any undercuts and or grooves therein. It also has a base        having a thin rod sprue connecting the base to the article        itself    -   b. A primary mold is created by inserting the part made in step        ‘a’ by hand or CAM into rubber mold slabs having top and bottom        portions. A mold is made of this model and thus the article can        be duplicated over and over again.    -   c. A wax or CAM part is created having a finished exterior        surface representing the finished article (ring in this example)        as it would be with both the alternative material and secondary        material together; thus, this part is completely full and is        without any undercuts and or grooves therein. It also has a base        having a thin rod sprue connecting the base to the article        itself    -   d. A production mold is created by inserting the part made in        step ‘c’ by hand or CAM into rubber mold slabs having top and        bottom portions. A mold is made of this model and thus the        article can be duplicated over and over again.    -   e. Then the production mold is utilized to create a finished        article over and over again. A ring or other article that has        been machined with grooves is filled with wax in the grooves        therein and is inserted into the production mold. A secondary        material such as gold or silver is injected into the mold with a        rapid burnout cycle thereby completing the article.

FIG. 4 represents a process flow diagram relating to the use of pins inco-casting an item. A pin is a hole in the inside surface of the itemthat reaches through the body of the item to the ridges above that areto be filled with secondary metal. This process includes:

-   -   A) A model is created using casting or CAM/CAD.    -   B) A primary metal model molded.    -   C) Primary metal is placed on wax sprues and pattern is filled        with wax.    -   D) Co-casted model is molded together.    -   E) Primary metal model (3A) is recreated and placed in secondary        mold and injected with wax and cast again to apply secondary        material to repeat the process.

Co-Casting Process

-   -   A) An original design is created with a recessed cut away area        connecting a pattern throughout the design.    -   B) The pattern must have certain criteria that will insure the        secondary metal over Black Ti (AM) or other AM will adhere to        the model. It should be noted that Black Ti is used an exemplary        metal and any other AM may be used in connection with the        process described herein.    -   C) The pattern may have a minimum depth of 0.4 mm and width of        generally less than 0.5 mm throughout the model; however, it        should be understood that these dimensions are only exemplary        amounts and that sizes greater or less than these are        contemplated.    -   D) The pattern must have an undercut in each pattern wall to        adhere secondary material.    -   E) The model is then created in Black Ti (AM) or any other        material defined as alternative using machining and or        traditional modeling and or Titanium casting methods.    -   F) The Black Ti (AM) model will be made into a mold for future        production.    -   G) The Black Ti (AM) model will be coated with wax, so as to        fill in the pattern, and then placed on a traditional investment        sprue.    -   H) The Black Ti (AM) model and wax combination is then cast at        temperatures ranging from 500° F. to 2900° F. with the secondary        metal using traditional jewelry investment in a rapid burnout        cycle of 4-5 hours.    -   I) The Co-cast model is removed from the investment and        immediately molded with both metals together.    -   J) The Co-cast design is cleaned and completed.    -   K) The process may then repeat at any of the aforementioned        steps.

This type of co-casting of precious metals gold (all Karats), silver,platinum and palladium, to what is defined as contemporary oralternative metals; including but not limited to: titanium and allrefractories (Niobium/columbium), zirconium, and Tantalum), stainlesssteel, chrome cobalt, Tungsten carbide, ceramics, etcetera. Thistechnique applies to consumer products and/or further for jewelry,giftware, personal and table top accessories, watches, and any form ofdecorative encasements. The combined piece made of precious metal and analternative material can be attached to giftware, accessories whereinthe attachment is through woodworking adhesive, screws, bolt, nut,welding, heat treatment, plastic or similar protrusion, and slotinsertion.

In an alternative embodiment of the present invention the co-castprocess is accomplished by creating a foundation in the contemporary (oralternative material). The reason being that it is generally thematerial with the higher melting point. The foundation product may beproduced in any number of methods, including casted, machined,fabricated, etched or otherwise. The foundation is prepared withrecesses, cavities, undercuts, holes or other openings that are createdto capture and secure the lower melting point or softer materials(precious metal or otherwise including copper, bronze, brass, etc). Oncethe foundation material has been properly cleaned and prepared for theaddition of secondary or more materials, wax or other burn out materialis inserted into the chosen areas. The wax may be inserted in any numberof methods including by hand, injected in molds (rubber or metal) orother. The next step is to place the piece with the wax inserted ontowhat the industry calls investment or other shell material. Thisinvestment or shell material is poured as a liquid into a canister alongwith the waxed metal foundation material. Once the liquid investment iscured and hardened the canister is place in an oven where the wax isburnt out and the molten metal of the secondary materials are poured into fill the cavities. The investment is then cooled and removed, leavingthe co-cast product ready to finish.

FINAL OPTIONAL METHOD for affixing the precious material to the AM. Bywrapping the wax around (more than half way) to completely around theAM. In doing this, once the precious material is melt around the AMportion, the base piece is trapped in the surrounding material.

The above-described embodiments are merely exemplary illustrations ofimplementations set forth for a clear understanding of the principles ofthe invention. Many variations, combinations, modifications orequivalents may be substituted for elements thereof without departingfrom the scope of the invention. Therefore, it is intended that theinvention not be limited to the particular embodiments disclosed as thebest mode contemplated for carrying out this invention, but that theinvention will include all the embodiments falling within the scope ofthe appended claims.

What is claimed is:
 1. A co-casting method comprising the steps of:creating an original design having a unique criteria with a recessedarea connecting a pattern in the original design.
 2. The co-castingmethod of claim 1, wherein the pattern has a minimum depth of 0.5 mm. 3.The co-casting method of claim 1, further comprising: ensuring theunique criteria enables a secondary metal adheres to a primaryalternative metal.
 4. The co-casting method of claim 3, wherein thepattern includes a side wall with an undercut to permit attachment of asecondary material.
 5. The co-casting method of claim 1, furthercomprising: making the original design into a mold.
 6. The co-castingmethod of claim 5, further comprising: creating a model using a metaland a pattern therein; and coating the pattern with wax filling.
 7. Theco-casting method of claim 6, further comprising: placing the model inan investment sprue.
 8. The co-casting method of claim 7, furthercomprising: casting the model with a secondary metal.
 9. The co-castingmethod of claim 8, further comprising: removing the model from theinvestment sprue and immediately molding it with both metals together.10. The co-casting method of claim 9, further comprising: cleaning andcompleting the model.
 11. A Co-Casting method comprising the steps of:creating a primary mold model having a plurality of recessed areastherein; filling the plurality of recessed areas in the primary moldmodel with a wax for secondary casting; and molding a precious metal inthe recessed areas and repeating the process.
 12. The Co-Casting methodof claim 11, wherein the recessed area is from a group comprising of: aridge, an undercut, a pin, and a rail.
 13. A co-casting processcomprising the steps of: providing a part with a depression throughoutan outside wall; molding a primary model is molded; filling the primarymodel with wax for secondary casting; and completing a co-cast as themetals are molded together such that the primary model is placed insidefor secondary wax injection to repeat process.